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Crimping Die Assembly 408- -4116 LOC B 1 of 4E2010 Tyco Electronics Corporation, Berwyn, PA All Rights Reserved TE logo and Tyco Electronics are trademarks. *Trademark. Other products names, logos, or company names might be trademarks of their respective owners. TOOLING ASSISTANCE CENTER 1- -800- -722- -1111 PRODUCT INFORMATION 1- -800- -522- -6752 This controlled document is subject to change. For latest revision and Regional Customer Service, visit our website atwww.tycoelectronics.com

11 MAR 10 Rev A58559- 1

Assembly 354940- -1 (Ref) Anvil Die Movable Jaw (Ref) Stationary Jaw (Ref) Locator Spring RetainerAdjustment Screw Die Retaining Screws (Ref) Nut Straightener Spring Indenter Die 1. INTRODUCTION Crimping Die Assembly 58559- -1 is designed to crimp Consumer RF Series BNC plug connectors when used in PRO- -CRIMPER III Frame Assembly 354940- -1. Read these instructions thoroughly before using the die assembly. Dimensions in this instruction sheet are in millimeters [with inches in brackets]. Figures are not drawn to scale. Reasons for reissue of this instruction sheet are provided in Section 8, REVISION SUMMARY. 2. DESCRIPTION (See Figure 1) The die assembly consists of an indenter die and an anvil die. The die assembly features a locator and straightener assembly (straightener, adjustment screw, nut, spring retainer, and spring). Each die is held in the tool jaws by a single screw. When mated, the dies form two crimping chambers. The small crimping chamber crimps the center contact onto the center conductor of the coaxial cable and the large crimping chamber crimps the ferrule of the connector onto the coaxial cable. The ferrule crimping chamber actually places two different size crimps on the ferrule; one crimp in the connector support sleeve area, and another crimp in the cable insulation area directly behind the cable braid. The locator and straightener assembly properly positions and holds the center contact of the connector during the crimping procedure. 3. INSTALLATION AND REMOVAL OF DIE ASSEMBLY (See Figure 1) 1. Close the tool handles until the ratchet releases, then allow the handles to open fully. 2. Remove the two die retaining screws from the tool jaws. 3. Install the anvil die in the movable jaw of the tool. Insert the short die retaining screw through NOTE i

408- 4116Crimping Die Assembly 58559- 1 Rev A2 of 4 Tyco Electronics Corporation the retaining hole in the jaw and through the anvil die. Tighten the screw just enough to hold the die in place. Donot tighten the screw completely at this time. 4. Install the indenter die in the stationary jaw of the tool frame. Insert the long die retaining screw through the retaining hole in the jaw and through the indenter die. Tighten the screw just enough to hold the die in place. Donot tighten the screw completely at this time. 5. Carefully close the tool handles, making sure that the dies align properly. Continue closing the tool handles until the tool ratchet has engaged sufficiently to hold the dies in place, then tighten both die retaining screws. The ratchet has detents that create audible clicks as the tool handles are closed. 6. Attach the straightener onto the spring retainer with the adjustment screw. Insert the spring into the spring retainer and place the locator over the spring. 7. While holding the locator against the spring retainer, place the screw hole in the spring retainer over the end of the long die retaining screw. The locator should be against the side of the tool jaw. 8. Place the nut onto the end of the long die retaining screw and tighten the nut enough to hold the locator and straightener assembly in place, but still allowing the locator to slide up and down. 9. To remove the die assembly, close the tool handles until the ratchet releases. Remove the nut, the locator and straightener assembly, and the two die retaining screws. Slide the anvil and indenter out of the tool jaws. 4. CRIMPING PROCEDURE Initially, the connector retention force should be verified as specified in Paragraph 5.2., Retention Force Adjustment, before using the tool. For detailed information on cable strip lengths and proper assembly of the connector, refer to the instructions packaged with the connector. Make sure that the connector ferrule has been placed onto the cable, and that the cable braided shield is flared away from the cable. Then proceed as follows: 4.1. Crimping the Center Contact(See Figure 2) 1. Holding the center contact by the mating end, insert the contact through the front of the tool and into the crimping chamber and onto the anvil die. 2. Close the tool handles so that the dies partially close. Position the contact so that the locator drops into the contact wire stop slot and the end of the contact is inside the groove in the straightener. See cross- -section of Figure 2. 3. Hold the contact in place and squeeze the tool handles together until the ratchet engages just enough to hold the contact in place. Do not deform the contact wire barrel. 4. Insert stripped cable into contact wire barrel until it is butted against the locator. See cross- -section of Figure 2. 5. Holding the cable in position, close the tool handles until the ratchet releases. Allow the tool handles to open fully and remove the crimped center contact. Figure 2 Crimping Center Contact Locator Positioned in Contact Wire Stop Slot End of Contact Positioned in Straightener Top of Locator Stripped Wire Anvil Die Cross- -Section Straightener Center Contact Anvil Die Locator Contact Wire Stop Slot NOTE i NOTE i

408- 4116Crimping Die Assembly 58559- 1 3 of 4Rev A Tyco Electronics Corporation The crimped center contact may stick in the crimping area, but the contact can be easily removed by pushing downward on the top of the locator (see Figure 2). 4.2. Crimping the Ferrule(Figure 3) 1. Insert the crimped center contact into the connector body until the cable dielectric butts against the dielectric inside the connector body or until the center contact is securely positioned within the connector. Make sure that the braided shield of the cable is over the support sleeve of the connector body and that no strands from the shield enter the connector body. 2. Slide the ferrule up over the braided shield and onto the connector until the ferrule butts against the shoulder on the connector body. 3. Place the ferrule in its crimping chamber of the anvil die so that the shoulder on the connector body butts against the edge of the die. 4. While holding the assembly together, begin to close the tool handles. Keep holding the assembly until the dies have closed enough to hold the assembly in place. Make sure that both sides of the ferrule are started evenly into the crimping chamber. DO NOT attempt to crimp an improperly positioned ferrule. 5. Carefully close the tool handles until the ratchet releases. 6. Allow the tool handles to open fully, and remove the crimped connector. 5. TOOL ADJUSTMENTS 5.1. Contact Support Adjustment Make a sample crimp and determine if the center contact is bending upward, bending downward, or bending from side to side. If the contact is bent, adjustment is required. 1. Loosen the adjustment screw. 2. Place a contact with cable into the proper crimping chamber and close the tool handles until the locator and straightener assembly is holding the contact in position. 3. Move the straightener up or down, as required, to eliminate the bending of the center contact. 4. Tighten the adjustment screw and close the handles until the ratchet releases. 5. Remove and inspect the center contact. 6. Make another sample crimp. If the contact is still being bent during crimping, repeat the adjustment procedure. 5.2. Retention Force Adjustment(Figure 4) The tool ratchet mechanism features an adjustment wheel with numbered settings. If the retention force is not acceptable, adjust the ratchet as follows: Refer to the appropriate Application Specification (114- -Series) for the required retention force of the connector. 1. Remove the lockscrew from the ratchet adjustment wheel. Figure 3 Ferrule in Crimping Chamber on Anvil Di e Shoulder of Connector Body Against Edge of Die Crimping Ferrule Cross- -Section Ferrule Anvil Die NOTE i CAUTION ! NOTE i